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FCS165

key word:Heat exchange element

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Product description

1. The relationship among FCS, PLC and DCS

FCS is developed from PLC; In other industries, FCS is developed from DCS, so there are countless links and essential differences between FCS and PLC and DCS.

FCS is developed from DCS and PLC. FCS not only has the characteristics of DCS and PLC, but also takes a revolutionary step. But at present, the new DCS and the new PLC have the tendency to approach each other. The new DCs has strong sequence control function; And the new PLC, in the treatment of closed-loop control is not bad, and both can form a large network, DCS and PLC scope of application, has a lot of cross.

The key of DCS system is communication. It can also be said that data highway is the backbone of DCS. Because its task is to provide communication network for all components of the system, the design of data highway itself determines the overall flexibility and security. The media of the data highway can be a twisted pair, coaxial cable or optical fiber cable.

Through the design parameters of data highway, we can basically understand the relative advantages and disadvantages of a specific DCS system.

① How much I/O information can the system handle.

② How much control loop information can the system handle.

③ How many users and devices can be adapted (CRT, control station, etc.).

④ How the integrity of the transmitted data is thoroughly checked.

⑤ What is the maximum allowable length of the data highway.

⑥ How many branches can the data highway support.

⑦ Whether the data highway can support the hardware (programmable controller, computer, data recording device, etc.) produced by other manufacturers.

In order to ensure the integrity of communication, most DCS manufacturers can provide redundant data.

In order to ensure the security of the system, the complex communication protocol and error detection technology are used. The so-called communication protocol is a set of rules to ensure that the transmitted data is received and understood as the same as the transmitted data.

At present, two kinds of communication methods are generally used in DCS system, namely synchronous and asynchronous. Synchronous communication relies on a clock signal to adjust the data transmission and reception, and asynchronous network adopts a report system without clock.

 

2. Key points of FCS

2.1. The core of FCS system is bus protocol, namely bus standard

A type of bus, as long as its bus protocol is determined, the related key technology and related equipment will also be determined. As far as the basic principle of its bus protocol is concerned, all kinds of buses are the same, which are based on solving the two-way serial digital communication transmission. However, due to various reasons, there are great differences in the bus protocols of all kinds of buses.

In order to make the fieldbus meet the requirements of interoperability and become a real open system, the user layer of IEC international standard and fieldbus communication protocol model clearly stipulates that the user layer has the function of device description. In order to achieve interoperability, each fieldbus device is described by device description DD. DD can be considered as a driver of the device, which includes all the necessary parameter descriptions and the operation steps required by the master station. Because DD includes all the information needed to describe the device communication and has nothing to do with the master station, it can make the field devices truly interoperable.

Whether the actual situation is consistent with the above, the answer is No. At present, there are eight types of Fieldbus international standard, but the original IEO international standard is only one of the eight types, which is equal to the other seven types of fieldbus. The other seven kinds of bus, no matter what the market share, each bus protocol has a set of software and hardware support. They can form systems and products, and the original IEC fieldbus international standard is an empty shelf without software support or hardware support. Therefore, it is almost impossible to realize the mutual compatibility and interoperability of these buses.

From the above, can we get such an image: the interoperability of open fieldbus control system is open and interoperable to its products as long as it follows the bus protocol of a specific type of fieldbus. In other words, no matter what manufacturer's products are, they are not the products of the fieldbus company. As long as they follow the bus protocol of the bus, the products are open and interoperable, they can form a bus network.

2.2. The foundation of FCS system is digital intelligent field device

Digital intelligent field device is the hardware support and foundation of FCS system. The reason is very simple. FCS system implements the two-way digital communication fieldbus signal system between automatic control device and field device. If the field device does not follow the unified bus protocol, that is, the relevant communication protocol, does not have the function of digital communication, then the so-called two-way digital communication is just empty talk, and can not be called fieldbus control system. Furthermore, one of the characteristics of fieldbus is to increase the field level control function. If the field device is not a multi-functional intelligent product, then the characteristics of the field bus control system will not exist. The so-called advantages of simplifying the system, convenient design, and conducive to maintenance are also virtual.

2.3. The essence of FCS system is information processing on site

For a control system, whether using DCS or fieldbus, the amount of information that the system needs to process is at least the same. In fact, with fieldbus, more information can be obtained from the field. The amount of information in the fieldbus system is not reduced or even increased, but the number of information transmission cables is greatly reduced. This requires, on the one hand, to greatly improve the ability of cable transmission of information, on the other hand, to allow a large amount of information to be processed on the spot, so as to reduce the information round-trip between the field and the control room. It can be said that the essence of fieldbus is the fieldization of information processing.

Reducing information round trip is an important principle in network design and system configuration. Reducing information round trips often brings the benefit of improving system response time. Therefore, in network design, priority should be given to the nodes with large amount of mutual information exchange in the same branch.

Reducing the amount of information going back and forth and reducing the number of cables in the system sometimes contradict each other. At this time, we should still make a choice based on the principle of saving investment. If the response time of the selected system allows, the cable saving scheme should be selected. If the response time of the selected system is tight, a little less information transmission is enough, then the scheme of reducing information transmission should be selected.

At present, some field instruments with fieldbus are equipped with many function blocks. Although the performance of the same function block of different products will be slightly different, there are many similar function blocks on a network branch. Which function block of field instrument should be selected is the problem to be solved in system configuration.

The principle to consider this problem is to minimize the round trip of information on the bus. Generally, you can select the function block on the instrument with the most information output related to the function.

 

 

3. Introduction of FCS165

The power station fieldbus control system FCS165 is an automatic control system of power station independently developed by Xi'an thermal Research Institute Co., Ltd. (China Huaneng Group Technology Center), whose goal is to realize the full digital automatic control, monitoring and management of 1000MW thermal power units. The system can also be used in the fields of industrial process control such as hydropower, chemical industry, paper making and cement. FCS165 system not only absorbs the advanced DCS technology, but also integrates the fifth generation automation control technology, fieldbus control technology, and integrates Profibus and FF technology conforming to international fieldbus standard IEC61158, which is the advanced technology equipment of the new generation digital power plant: fieldbus control system.

FCS165 system has been integrated into the control technology and optimization experience of thermal power plant of Xi'an thermal Research Institute for more than 40 years. It is advanced in technology, reliable in performance, and can meet the needs of power plant to the greatest extent in function, and has friendly human-computer interface, which conforms to the operating habits of engineering configuration personnel and power plant personnel.

Xi'an thermal research institute is a national research organization of thermal power science and technology and thermal power generation technology development in China. In 2003, it became a limited liability company controlled by China Huaneng Group, which was jointly owned by China Datang Group, China Huadian Group, China national power group and China Electric Power Investment Group, and was officially renamed Xi'an thermal Research Institute Co., Ltd. The scientific and technological team of Thermal Engineering Institute is strong, skilled and tenacious in style, and the test facilities and experimental equipment are advanced and complete. It has the National Engineering Research Center for clean combustion of boiler coal of power station set up by the national development and Reform Commission, and is the supporting unit of the technical center of China Huaneng Group Company, and has branches in Beijing and Suzhou; The Institute also has master degree award point and post doctoral workstation, and is also the affiliated unit of thermal power generation branch of China Electrical Engineering Society, 7 industry standardization technical committees, 5 industry centralized quality testing centers, and the main unit of thermal power generation, the national core Chinese Journal.

 

4. System overview of FCS165

FCS165 system is equipped with three-layer communication network. The top layer is information network (100m switched Ethernet), which is non real-time and management data channel, and connects to the factory level information network; The middle layer is the unit main control communication network (100m switched Ethernet), which is a real-time and control data channel, which connects DPU, operator station, engineer station and historical data station; The lower layer is i/o and fieldbus communication network, which is the field process parameters, status, diagnostic data channel, and connects i/o modules, fieldbus instruments and equipment. See Figure 1 for the network structure.

The most remarkable feature of FCS165 system is to realize the seamless connection between DCs and fieldbus network. Profibus-DP communication master module and FF-H1 communication master module can be directly inserted into the i/o slot adjacent to the controller, and the data can be exchanged with the controller through the parallel bus of the backplane. The intelligent equipment of Fieldbus can be directly hung on the corresponding communication network segment.

4.1. System scale

Main control communication network: redundant structure; DPU has 50 maximum redundant nodes, 50 maximum operator station / engineer station nodes (redundant channels), and 27 historical data station nodes. The distributed database structure without server is adopted, and the operator stations are peer-to-peer.

Information network: redundant structure; 254 maximum network nodes.

DPU: redundant configuration of controller; 5-layer i/o rack, 58 i/o modules can be inserted, and 928 points of traditional i/o point can be inserted. 3 pairs of redundant Profibus-DP communication master stations can be inserted to form 3 pairs of independent redundant Profibus-DP main network sections; Four FF-H1 communication master stations can be inserted, which constitute 16 FF-H1 network segments (each master station manages 4 FF-H1 network segments).

Database: the real-time database capacity and historical database capacity can reach 100000 points.

 

4.2. Controller

The core of DPU is controller FCP01, 32-bit embedded thin instruction set (RISC) CPU, and the operation speed is 200mips (basic operation instruction cycle 5ns/ time). Fast memory (SDRAM) 128MB, flash 32MB. Power consumption 4.2w. The system integrates redundant 100Mbps Ethernet interface, embedded real-time multitask operating system, and has rich functional block algorithm for power station control and field bus data processing function. The operation scan cycle is the fastest 20ms, and the configuration logic of 5 operation cycles can be processed simultaneously.

 

4.3.  I/O card accuracy

Analog input card: 4 ~ 20mA (1 ~ 5V) 0.1%; TC, RTD (MV signal) 0.2%

Analog output card: 4 ~ 20mA (1 ~ 5V) 0.2%.

SOE card: resolution 1ms; The resolution of SOE card between different DPUs can reach 1ms through GPS time synchronization

4.4. Embedded fieldbus system

DPU can be inserted into Profibus-DP communication master (FPB01 module), FF-H1 communication master (FFH01 module) and I/O module at the same time;

Fieldbus communication master and controller FCP01 exchange data through backplane parallel bus; The data, status and diagnosis information of Fieldbus equipment directly enter FCP01 real-time database, which can be used for configuration control and operation together with traditional I/O signal.

The software tools for configuration, monitoring, debugging and diagnosis of Profibus network, master station and slave station integrated with engineer station adopt the interface style of Windows Resource Manager( (see Figure 2)

4.5. Adapt to industrial environment

The hardware design and manufacture of FCS165 system meet the operation requirements of industrial environment of thermal power plant.

4.5.1. Electromagnetic compatibility: electrostatic discharge passes industrial level 3 test (contact discharge) ± 6000V, air discharge ± 8000V); Surge impact passed industrial level 2 test( ± 1000V); Electrical fast transient pulse train passed the industrial level 2 test( ± 1000V); Voltage sag and short-time interruption passed industrial test. The above tests are carried out in accordance with the national standard GB / T 1762. X (equivalent to IEC6100-4-X).

4.5.2. Environmental conditions:

Normal working environment temperature: I/O module   -10℃~+70℃; Power supply - 10 ℃ ~ + 55 ℃;

Normal working environment humidity: 10-96% (no condensation).